ASB EC135-62A-029

Effective for version(s): T1, T2, T2+, P1, P2, P2+

635 T1, 635 T2+, 635 P2+

ALERT SERVICE BULLETIN

SUBJECT: MAIN ROTOR SYSTEM -- Main Rotor Hub-Shaft
Visual inspection of the upper and lower hub-shaft flange for cracks

Revision number Issue date

Revision 0 2012-03-08

Revision 1 2012-05-16

Revision 2 2012-05-17

Revision 3 2012-08-09

Revision 4 2012-08-23

Revision 5 2012-09-10

Revision 6 2012-10-02

Revision 7 2012-10-22

Revision 8 2015-04-22

Summary:
During a PERIODICAL INSPECTION a crack was detected on the lower hub-shaft flange of a main
rotor hub-shaft. Since Revision 0 of this Alert Service Bulletin was published, 4 additional cracks have
been discovered during preflight inspections.

Reason for the Revision:

Revision 8 limits the effectivity range of this Alert Service Bulletin to the main rotor hub-shafts
mentioned in Section 1.A.1.(b). The previously required visual inspection remains unchanged for
these main rotor hub-shafts.
With the help of Service Bulletin EC135-62-036, the affected main rotor hub-shafts can be modified;
thereafter, they are no longer affected by ASB EC135-62A-029.

Compliance:
Compliance with this Alert Service Bulletin is prescribed. See Section 1.E.

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ASB EC135-62A-029
1. PLANNING INFORMATION

1.A. EFFECTIVITY

1.A.1. Helicopters/installed equipment and parts

(a) EC135, T1, T2, T2+, P1, P2, P2+, 635 T1, 635 T2+, 635 P2+, all S/N equipped with main
rotor hub-shafts with more than 400 FH TSN* or 400 FH TSR**.
* Time Since New
** Time Since Rework -- rework (L623M1001881) carried out in accordance with SB EC135-62-030 or SB EC135-62-032

Rework not carried out -- affected Rework L623M1001881 carried out -- affected

(b) Main rotor hub-shaft,

pre-assembled with DMS: L623M1003102
L623M1003103
L623M1003104
L623M1006101
L623M1006102
L623M1006103
L623M1203103
L623M1206102
L623M1206103

NOTE:

All those main rotor hub-shafts are excluded which have

additionally been identified with ”L623M1003881” (see
illustration on the right), proving that the rework with the
corrective measure has already been accomplished.

Main rotor hub shaft identified with

L623M1003881 are not affected.

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ASB EC135-62A-029
1.A.2. Non--installed equipment and parts
Not applicable.

1.B. ASSOCIATED REQUIREMENTS

Not applicable.

1.C. REASON
During a PERIODICAL INSPECTION a crack was detected on the lower hub-shaft flange of a
main rotor hub-shaft. Since Revision 0 of this Alert Service Bulletin was published, 4 additional
cracks have been discovered during preflight inspections.
-- Revision 0 prescribed a one-time visual inspection.
-- Revisions 1 and 2 introduced the following measures:
→ Part 1: an associated preflight inspection
→ Part 2: a repetitive visual inspection
→ Part 3: a visual inspection requiring the removal of the components, the nuts and the
washer.
-- Revision 3 of this Alert Service Bulletin is based on the experience and results gained from
the full scale component test:
→ Part 1: The preflight inspection is part of the Flight Manual. Additional, supporting
material has been added to this ASB with regard to the pre-flight inspection to be
carried out in accordance with the FLM.
→ Part 3: No longer required and has therefore been removed.
-- The following changes were introduced with Revision 4:
→ Part 2: Increase of the visual inspection interval from 10 FH to 15 FH.
→ Description of the inspection requirements for those main rotor hub-shafts on which
SB EC135-62-030 and/or SB EC135-62-032 have been carried out.
-- The following change was introduced with Revision 5:
→ Part 2: Increase of the visual inspection interval from 15 FH to 25 FH.
-- The following change was introduced with Revision 6:
→ Part 2: Increase of the visual inspection interval from 25 FH to 40 FH.
-- The following change was introduced with Revision 7:
→ Part 2: Increase of the visual inspection interval from 40 FH to 50 FH.
-- Revision 8 restricts the range of affected main rotor hub-shafts.

1.D. DESCRIPTION
If necessary, remove the rotor hub cap and the transmission fairings. Visual inspection of the
upper and lower hub-shaft flange. If previously removed, re-install the rotor hub cap and the
transmission fairings.

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ASB EC135-62A-029
1.E. COMPLIANCE

1.E.1. Compliance at H/C manufacturer level

Helicopters/installed equipment and parts
Not applicable.
Non--installed equipment and parts
Not applicable.

1.E.2. Compliance in service

Helicopters/installed equipment and parts:

EFFECTIVITY All helicopters.

Part 1: Preflight check -- Blade attachment area of main rotor mast (upper and
lower)
With Revision 8 of this Alert Service Bulletin, the reference to the preflight check has been
eliminated, since the preflight check has already been incorporated into the FLM.

Part 2: Visual inspection of the upper and lower hub-shaft flange:

The visual inspection of the upper and lower hub-shaft flange must continue to be carried
out every 50 FH in accordance with Section 3.B, Part 2.

Part 3: Visual inspection of the blade bolt area:

Revision 3 eliminated the inspection requirement.

Non--installed equipment and parts

Not applicable.

1.F. APPROVAL
Approval of modifications:
The technical content of this document is approved under the authority of
DOA No. EASA.21J.034.

1.G. ESTIMATED MAN--HOURS

Qualification Mechanic Electrician Pilot Others

Time approx. 0.5 h -- -- --

1.H. WEIGHT AND BALANCE

Not applicable.

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1.I. POWER CONSUMPTION
Not applicable.

1.J. SOFTWARE UPGRADES/UPDATES

Not applicable.

1.K. REFERENCES
AMM EC135 and AMM EC135/635
FLM EC135/635

1.L. OTHER AFFECTED PUBLICATIONS

Not applicable.

1.M. INTERCHANGEABILITY OR MIXABILITY OF PARTS

Interchangeability:
Not applicable.
Mixability:
Not applicable.

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2. MATERIAL INFORMATION

2.A. MATERIAL: PRICE -- AVAILABILITY -- PROCUREMENT

Not applicable.

2.B. INFORMATION CONCERNING INDUSTRIAL SUPPORT

Not applicable.

2.C. MATERIAL REQUIRED PER HELICOPTER/COMPONENT

Not applicable.

2.D. MATERIAL TO BE RETURNED

Not applicable.

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ASB EC135-62A-029
3. ACCOMPLISHMENT INSTRUCTIONS

3.A. GENERAL

Part 1 Part 2
(Preflight inspection in (Visual inspection)
accordance with the FLM) Every 50 FH
Before every flight
Main rotor hub-shaft with less than X Not applicable
400 FH TSN
Main rotor hub-shaft with less than X Not applicable
400 FH TSR
after the last execution of
SB EC135-62-030
and/or
SB EC135-62-032
Main rotor hub-shaft with more X X
than
400 FH TSN
Main rotor hub-shaft with more X X
than
400 FH TSR
after the last execution of
SB EC135-62-030
and/or
SB EC135-62-032

3.B. WORK STEPS

Part 1: Preflight check -- Blade attachment area of main rotor mast (upper and
lower):
With Revision 8 of this Alert Service Bulletin, the reference to the execution of the preflight check
has been eliminated, since the preflight check has already been incorporated into the FLM.

Part 2: Visual inspection of the upper and lower hub-shaft flange:

A. Preliminary steps:
(1) If necessary, remove the rotor hub cap i.a.w. AMM, 62-31-00, 4-1.
(2) If necessary, remove LH and RH transmission fairing i.a.w. AMM, 71-11-00, 4-4.

B. Inspect the upper and lower hub-shaft flanges for cracks:

(1) Clean the visible area of the upper and lower hub-shaft flanges of the main rotor
hub-shaft i.a.w. Figure 1 and inspect for cracks. If necessary, use a flashlight and a
mirror. Paint irregularities must be examined with a magnifying glass or a micro camera.

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ASB EC135-62A-029
(2) If cracks are detected during the visual inspection, contact AHD customer support. The
rotor hub-shaft must be replaced before the next flight.

(3) If previously removed, install rotor hub cap i.a.w. AMM, 62-31-00, 4-1.

(4) If previously removed, install LH and RH transmission fairing i.a.w. AMM, 71-11-00, 4-4.

C. Confirm accomplishment of Part 2 i.a.w. Section 3.C.

Part 3: Visual inspection of the blade bolt area:

Revision 3 eliminated the inspection procedure.

3.C. IDENTIFICATION
Compliance with this document:
Confirm accomplishment of this Alert Service Bulletin by an entry in the historical record of the
helicopter and in the log card of the main rotor hub-shaft:
Part 2:
”Visual inspection of the upper and lower hub-shaft flanges”

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3.D. OPERATING AND MAINTENANCE INSTRUCTIONS
Flight Manual:
In the meantime, the temporary revisions have been incorporated into all FLMs.
AMM/Aircraft Maintenance Manual:
No changes.

4. APPENDIX
Not applicable.

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Upper hub-shaft flange

Lower hub-shaft flange

Main rotor hub-shaft

Inspect the visible area of the upper and lower hub-shaft flanges.

Main Rotor Hub-shaft -- Upper and Lower Hub-shaft Flanges

Figure 1

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